Recovery of catalysts



March 9, 1948. FRA'GEN 2,437,352

RECOVERY OF CATALYSTS Filed D90. 29, 1945 26 COOLER 62 PREC/P/TA TOPS RE GE NE RA TOR 7b Slack 76 Frucf/on al'or COOLER Gas 7'0Sfack 4 COOLER Carr/er G0 4 42 l 53 I n Venfor.-

Na/han Fragen Patented Mar. 9, 1948 2.437.352 nncovnny F CATALYSTS Nathan Fragen, Hammond, Ind., assignor to Standard Oil Company, Chicago, 111., a corporation of Indiana Application December 29, 1945, Serial No. 638,416

6 Claims. (01. 196-52) This invention relates to the conversion of hydrocarbons in the presence of contact catalysts and more particularly it relates to a process of converting hydrocarbons by contacting in the vapor phase with fluidized masses of metal oxide conversion catalysts where the catalyst is maintained in dense fluid suspension. In this'process, carbon which is deposited on the catalyst during the conversion operation is removed by passing the catalyst in a fluidized stream to a regeneration zone where the carbonaceous deposits are burned off with oxygenand then the regenerated catalyst is returned to the hydrocarbon conversion zone.

The object of the invention is to provide a method and means for eliminating from such a suspension that part of the catalyst which is degenerated in conversion activity while retaining the remainder of the catalyst within the system. By effecting such elimination of degenerated catalyst, the efliciency of the operation, the thruput capacity, and the economy are increased. A more favorable product distribution is also obtained with elimination of the degenerated catalyst, i. e., less gas and carbon are formed and more gasoline results incracking heavy oils such as as oil.

The invention is illustrated by a drawing which shows diagrammatically an apparatus for carrying out the process. Referring to the drawing, a.

2 usually with silicon oxide. Various natural products may be employed as catalysts, particularly clays such as acid-treated montmorillonite clay known as Super Filtrol. The synthetic catalysts are usually prepared by precipitation of metal oxide or hydroxide from salt solutions or by gelation of a suitable metal oxide sol such as silica sol. Silica gel is frequently employed as a component of hydrocarbon cracking catalysts. The catalyst gel may be prepared in a massive form and subsequently granulated to the desired size or the gel may be initially prepared in the form of fine particles of suitable dimensions after drying. A microspherical gel catalyst such as silica gel promoted with aluminum or magnesium oxides having a particle size of 20 microns upwards to 200 or 300 microns is particularlysuitable for this process. In general, the catalysts employed in fluidized solid contact processes of this kind have a particle size of from 2 to 200 microns diameter. A typical sizr analysis of a Super Filtrol in an operating cracking unit of 10,000 barrels daily capacity is a follows:

knock rating,. heavy naphtha may be charged.

Where the feed is charged in the vapor phase, the vapors will usually be at a temperature of about 800 to 1000 F. Where the feed is in liquid phase or partly liquid phase, it is instantly vaporized by contact with hot regeneratedcatalyst from line l3 which may be at'a temperature of 900 to In reactor l2, the upflowing hydrocarbon vapors come in contact with a mass of fluidized conversion catalyst in dense suspension in the lower part of the reactor. The vapors flowing upwardly thru the reactor at a. velocity of about 0.5 to 4 feet per second serve to maintain the catalyst in turbulent agitation. ployed in the reaction are usually siliceous but various metal oxides may be used such as oxides of aluminum, magnesium, zirconium. boron, chromium, molybdenum, and mixtures thereof,

Catalysts em Finer than 250.

, The density of the catalyst suspension in the,

dense phase of reactor I2 is ordinarily about 15 to 25 pounds per cubic foot. In the upper part of the reactor above the dense phase level, a dilute catalyst phase exists in which the suspension of catalyst is of quite low density, generally well l below one pound per cubic foot. The converted hydrocarbon vapors are discharged thru cyclone separator [4 which serves to knock back most of the catalyst carried off in the dilute phase with the vapors. line l5 to a suitable fractionating system not shown'where gasoline and other desired products are "recovered. Catalyst carried ofi with these.

' vapors is usually recovered as a slurry and may The denuded vapors then vpass by pose of the stripping being to remove volatllizable hydrocarbons as far as feasible and prevent their access to the regeneration stage. The catalyst stream is then picked up by a current of air or other suitable conveying gas introduced by line '8 and the resulting suspension flows thru duct l9 into the base of regenerator 20 wherein it is distributed by perforated grid plate 2i. In regen erator 20, the catalyst is held in dense suspension, the density being similar to that maintained in reactor l2. In the presence of the oxidizing gases in regenerator 20, carbonaceous deposits are converted largely to CO. CO: and H20 which pass off with the regeneration gases. The reaction is highly exothermic and care must be taken to prevent overheating and damage to the catalyst. The temperature in the regenerator is usually held at about 1000 to 1200" F. by various methods of control such asby cooling and recycling a portion of the catalyst. Regeneration is usually not carried to the point of complete carbon removal, about 0.2 to 0.5 per cent of carbon being left on the catalyst.

As in the reactor, the upper part of the regenerator is occupied by a dilute phase suspension of the catalyst in the regeneration, gases. This catalyst is largely recovered from the regenerator by suitable cyclone separators as indicated. Thus the gases may be required to flow thru three cyclones in series before leaving the regenerator. The drawing shows two such series arranged in parallel, the dilute catalyst suspension entering cyclones 22, thence thru cyclones 23 and finally thru the third stage cyclones 24, the gases finally passing out by line 25. These gases, freed of most all catalyst having a particle size above 20 microns diameter, may be discarded to the atmosphere by line 26 or further treated in an electrical precipitator 21 to which the gases are conducted by line 28.

The catalyst knocked back in cyclones 22, 23 and 24 may be returned to the dense catalyst phase in the lower part of the Iegener-ator by dip legs 29, 30 and 3|, respectively. or a part or all of the returned catalyst from any one or more banks of cyclones may be diverted into catalyst receiver 32 connected by pressure-equalizing line 33 to cyclone outlet 25. From receiver 32 the catalyst flows by transfer line 34 to electrical precipitator 35 where a separation is made between the catalyst of high activity and the catalyst of low activity. A current of.steam, air. or other gas is introduced by line 36 as a carrier to convey the catalyst into the precipitator 35. A conditioner gas. particularly ammonia, may be added at 31 to assist in the electrical separation. Aeration gas, suitably air or steam. is introduced at the base of the precipitator by line 33. When ammonia is employed as a conditioner, the amount may suitably be about 1 to pounds per 100,000 pounds of gas passing thru the precipitator.

In the precipitator 35. the catalyst is maintained in suspension in dilute phase in the upper part of the precipitator and in the precipitation tubes 39. The velocity of the gases flowing upwardly thru the tubes is just suflicient to maintain the catalyst in suspension and prevent its settling under the influence of gravity. This velocity is only slightly greater than that which may be calculated from Stokes equation, viz:

KD'p p =gas velocity: D=diameter of solid particle;

4 r=gas viscosity; =density or solid particle: K=constant.

For my purpose, it is satisfactory to employ a vapor velocity of about 10 to per cent greater than that calculated, based on the size of the coarsest ten per cent of the catalyst charged to the precipitator. Best results are obtained by the treatment of catalyst having a narrow range of particle size. It is preferred to treat catalyst having a particle size range of about 30 to 80 microns diameter but good results are also obtainable with a somewhat larger range of particle size such as a catalyst in which at least 90% falls within the particle size range of 20 to 100 microns diameter. For catalyst particles greater than 20 microns diameter, a catalyst wherein 75% of the particles fall within about a 50 micron range is preferably treated in the electrical precipitator for the removal of degenerated material.

As the catalyst suspension passes thru precipitation tubes 39 where it is subjected to a high voltage electrical field resulting from the tension between the walls of the tubes and central electrodes, the active catalyst is flocculated and falls countercurrently to the gas stream into the base of the precipitation chamber whence it is withdrawn by line 40 leading to catalyst recycle line 4|, thru which the catalyst is driven by a current of air or other carrier gas introduced at line 42 back to' the regenerator 20. High tension electricity for energizing the'electrodes in precipitation tubes 39 is supplied thru lead 43. For this purpose a-pulsating-direct current of about 50,000 to 100,000 volts, with a pulsation frequency of 60 or cycles per second, is suitable.

The catalyst which is rejected in precipitator 35 passes with the gases by line 44 to cyclone separator 45 where the degenerated catalyst is recovered and the gases are vented by line 46. Degenerated catalyst is withdrawn by line 41 and may be employed for other purposes such as decolorizing certain types of oils. as a filler in roadmaking material. etc. Thereason for the selective action of the electrostatic field is not understood, but there is some indication that iron deposits on certain catalyst particles reduce their tendency to flocculate. The nature of the carbon deposit may also be a factor. The principal observed fact is that degenerated catalyst which gives a bad distribution of products is less readily flocculated.

The catalyst having the desired particle size range may be obtained for treatment in separator 35 by selecting the catalyst knocked back in the different cyclones 22, 23 and 24, the coarser catalyst being knocked back by cyclone separator 22 and the finer by cyclones 24. Thus, the catalyst recovered in cyclones 24 will usually consist largely of particles in the range of 20 to 60 microns diameter.

In addition to the treatment of catalyst knocked back from the dilute phase of the regenerator, I may also apply the electrical separation to catalyst withdrawn from the dense phase in the base of regenerator 20, Referring to the drawing, catalyst is removed from the regenerator by line 48, aerated by a suitable aeration gas in by line 10. Active catalyst recovered in 52 is recycled by lines GI and II to regenerator 20.

The drawing shows the current of gases and catalyst being introduced into precipitator 52 in a tangential direction, thus providing a centrifugal separating action within the precipitator and -efi'ecting separation of the coarser catalyst particles without bringing them into the electrical field within the precipitation tubes. As a result, more accurate control of precipitating conditions within the tubes is attainable. Other means may be employed for separating from the catalyst withdrawn by line 8 a fractiorfhavlng a desired narrow particle size range, preferably within 40 microns diameter. It is not necessary that the largest catalyst particle in the precipitator charge be no greater than 50 microns lar er than the smallest catalyst particle but only that the main portion of the catalyst, i. e. about 75 per cent, lie within a. 50 micron range oi. particle diameters. Some degree or separation of inactive catalyst can be obtained in precipitator 52 by treating the average catalyst directly as withdrawn by line 4!.

Where the catalyst employed is substantially 'iree of material having particle sizes below 20 microns, I have found it unnecessary to employ an electrical precipitator for treating the spent regeneration gas withdrawn by line 25 since the cyclone separators recover most of the catalyst coarser than 20 microns diameter. In case of natural catalysts such as Super Flltrol. however, and in case of certain synthetic catalysts lacking suiiic'ent physical strength to prevent mechanical breakdown to particles having dimensions below 20 microns diameter, it may be desirable to employ an electrical precipitator to recover such catalyst. Precipitator 21 is shown for this purpose. The oil gases. substantially free of catalyst, are discharged by line 62 and the recovered catalyst is conducted by line 63 to recycle line 4| as hereinabove described. Aeration gas can be introduced at line 0|.

Having thus described my invention what I claim is:

1. The process of separating degenerated catalyst from a fluidized solid catalyst hydrocarbon conversion system in which a finely divided catalyst is regenerated by oxidation oi carbonaceous deposits in a regeneration zone containing a dense fluidized suspension of catalyst in the lower part thereof and a dilute catalyst phase in the upper part, the improvement which comprises recovering catalyst from regeneration gases in said dilute phase by centrifugal action, redispersing said recovered catalyst in dilute suspension in a gas and passing said dilute suspension through an electrostatic field at a velocity sufilcient to carry particies of degenerated catalyst thru said field while retaining the particles oi active catalyst and recoveringsaid retained active catalyst for further use.

2. The process of claim 1 wherein the dilutev phase catalyst suspension in said regenerator I conducted thru a series 0! centriiuzal stages and 6 the recovered catalyst from one or said stages is alone subiectedto the action of said electrostatic field.

3. In the process of converting hydrocarbons bythe action or fluidized, finely divided, solid catalyst, wherein said catalyst is periodically sublected to oxidation to remove carbonaceous dep sits and regenerate it for further use, said oxidation being eiiected by forcing an oxygen-containing gas upwardly thru a mass of said catalyst in dense phase suspension in a regeneration zone, the method of separating permanently degenerated catalyst particles irom said catalyst mass which comprises withdrawing catalyst from said dense phase suspension, cooling it to about 350 to 650 It, injecting additional gas into said dense phase catalyst stream sufilcient to produce a dilute phase suspension, passing said dilutephasc suspension thru an electrostatic field and controlling the velocity of said suspension within said field and the intensity of said field to eflect flocculation and recovery of active catalyst particles in said suspension while rejecting degenerated catalyst particles which pass through said field, and thereafter recycling said recovered active catalyst particles to the conversion operation.

4. The process or claim 3 wherein said catalyst withdrawn from the dense phase suspension in said regeneration zone is classified to provide a traction having a selected narrow range or particle size and said fraction is subjected to separation in said electrostatic field.

5. The process oi claim 3 wherein said catalyst withdrawn from the dense phase suspension in said regeneration zone is classified to provide a fraction at least per cent of the particles of which have a diameter falling within the range of 20 to microns.

6. The process of separating degenerated catalyst from a fluidized solid catalyst hydrocarbon conversion system in which a finely divided catalyst is regenerated by oxidation or carbonaceous 4 deposits by contacting a suspension or said catalyst with an oxygen-containing gas in a regeneration zone, the improvement which comprises recovering from regeneration gases substantially all catalyst having particle sizes above about 20 microns diameter while discarding with said gases catalyst having particle sizes less than about 20 microns diameter, redispersing said recovered catalyst in dilute suspension in a gas and passing said dilute suspension thru an electrostatic field at a velocity sufllcient to carry particles or degenerated catalyst thru said field while retaining the particles of active catalyst and recovering said retained active catalyst for further use.

NATHAN FRAGEN.

REFERENCES CITED The following references are 01' record in the file of this patent:

OTHER REFERENCES "Improved Fluid Process for Catalytic Cracking," by E. V. Murphree et al., National Petroleum News, March 7, 1945; pages R 194, 195, 198, I,

202 and 304. 

